Bulk container

ABSTRACT

A bulk container and method of use for storage of at least two substances includes a first container for containing a first substance, and a second container for containing a second substance. The first container has an outer surface including a recess, and the second container has a shape corresponding with the recess of the first container. The second container is coupled with the recess to form a container assembly. The first substance and second substance are kept separate when in the first and second containers respectively.

FIELD OF THE INVENTION

The present invention relates generally to containers, and more particularly to containers for transporting bulk flowable materials.

BACKGROUND OF THE INVENTION

Flowable materials, such as liquids, granulated solids and the like, are often shipped or transported in bulk containers. In some cases, it is desirable to store or transport flowable materials in separate containers for later combination at their destination or place of use. It is an aim of transporters of such flowable materials to ship such separate containers in an efficient and convenient manner, and to ensure that the materials are kept separate until reaching an appropriate time and/or place for mixing the materials.

SUMMARY OF THE INVENTION

The present invention provides a bulk container that allows transport of at least two flowable materials isolated from one another in a common or unitary package. The flowable materials are transported in separate containers, with the separate containers being nested or coupled to form a container assembly. The separate flowable materials may then be mixed at a later time, such as at a final destination.

In one embodiment of the present invention, a bulk container and method for storage of at least two substances includes a first container adapted to contain a first substance, the first container having an outer surface with a recess. The bulk container further includes a second container adapted to contain a second substance. The second container has a shape at least generally corresponding with the recess of the first container. The second container is coupled with the recess to form a container assembly, so that the first substance and the second substance are kept separate when in their respective containers, such as during transport or shipping.

In one aspect, the bulk container may also include a cage for the first and second containers. The cage includes a base portion to support a bottom portion of the first container, a wall substantially surrounding the first container, and an upper outer perimeter that extends above the first container when the first container is in the cage. The wall may, for example, be a four sided wall with a square or rectangular cross section, such as for defining a substantially cubic cage.

In another aspect, the upper outer perimeter of the cage may be substantially open, such as to allow the first container to be freely lowered into or raised out of the cage.

In another aspect, the recess in the outer surface of the first container may be located at a top portion of the first container, so that the second container is removable through the opening at the upper outer perimeter of the cage, such as by lifting the second container out of the cage and away from the first container. Thus, placing the recess at the top portion of the first container may allow for the second container to be removed from the cage without removing the first container.

In yet another aspect, the cage may include a plurality of apertures passing through the wall at the upper outer perimeter. Such apertures may be used to tie the cage to an adjacent surface or support, such as a pallet. Alternatively, the apertures may be used to lift the cage, such as with an overhead crane or forklift or the like.

In still another aspect, the recess in the first container may be located adjacent to the wall of the cage when the first container is in the cage, so that the second container is located between the outer surface of the first container and the inner surface of the wall of the cage when the second container is coupled with the recess. When the recess is so configured, the second container is restrained from lateral movement when located in the cage with the first container, but is freely laterally removable from the first container when the first container is not located in the cage.

In another aspect, the first container may include a drain valve assembly located at a bottom portion of the first container. The drain valve assembly may be used for dispensing the contents of the first container. Such dispensation may optionally occur when the first container is located in the cage, such as through a door or cover in the wall portion of the cage.

In yet another aspect, the first container may have a capacity of at least 454 liters, but not more than 3,000 liters, and the second container may have a capacity of 10 liters. Either the first container or the second container or both may be made of an elastomeric material, such as polyethylene.

In still another aspect, the first container may include a sealable aperture at a top portion of the first container, such as an aperture threadably attached to a cap with a gasket disposed between the threaded aperture and the cap. Multiple apertures may be provided, such as two small apertures and one large aperture in the top portion of the first container for rapid and efficient fluid transfer into or out of the first container.

In another aspect, the outer perimeter of the first container may have four corner portions with a recess being located at each corner portion, so that the first container has four recesses. Each of the recesses may then be used for coupling a second container with the first container, so that the bulk container includes four second containers each located in a respective recess of the first container.

Accordingly, the present invention provides a bulk container adapted to transport and/or store more than one flowable material separately in a common package. The separate flowable materials are prevented from mixing during transport or storage, but can easily be mixed when ready to use. A cage may be provided that protects the container and facilitates safe, orderly and efficient movement and/or packing of one or more bulk containers.

These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a bulk container in accordance with the present invention;

FIG. 2 is an enlarged view of a portion of the bulk container shown in FIG. 1, illustrating a container; and

FIG. 3 is an enlarged view of a portion of the bulk container shown in FIG. 1, illustrating a drain valve assembly.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now specifically to the drawings and the illustrative embodiments depicted therein, a bulk container 10 for storage of at least two substances includes at least two containers, such as a first or main container 12 and one or more second or secondary containers 14. Secondary containers 14 nest or couple with a recess or bay or depression 16 formed in first container 12 to form a container assembly that is storable and/or transportable as a single unit while holding two or more flowable materials separately from one another.

The first or main container 12 has a closed body shape forming a cavity therein. The first container wall has generally vertical parallel wall portions 12 a with generally horizontal top portion 20 and bottom portion 12 b. In the illustrated embodiment, the top portion 20 has a slight convex curvature, such as for structural rigidity and to leave a gap or space between the inside or lower surface of the top portion and the material contained by the container when the container is filled to near-capacity. Transitions between the bottom, top and wall portions of first container 12 are radiused to provide rounded corners and edges to facilitate handling of first container 12 and to reduce stress concentration created by pressure on such corners and edges. For example, the radius between the bottom portion and the wall may be larger than the radius between top portion and the wall to accommodate the pressure exerted by the weight of contained materials on the bottom portion.

In the illustrated embodiment, first container 12 has a generally cubic shape with each of four rounded vertical corners having a recess 16 formed in a top portion 20 of the first container 12 for coupling with up to four second containers 14. However, it will be apparent to one skilled in the art that the first container may take other shapes, such as a cylindrical or hemispherical shape, without departing from the spirit and scope of the present invention.

Offset portions in the wall of first container 12 define recesses 16. The recesses have a horizontal platform 16 a offset from the bottom portion 12 b and a plurality of vertical wall portions 16 b offset inwardly from the outermost wall of the first container. For example, recesses 16 have three vertical walls, made up of two mutually opposed wall portions 16 b offset from the adjacent outer wall portions 12 a of the first container 12, and a middle wall portion 16 c offset from the corner defined by such adjacent wall portions. The mutually opposed end wall portions 16 b of the recess 16 may be at generally right angles with respect to one another, with the middle wall portion 16 c being at a 45-degree angle with respect to each adjacent end wall portion 16 b.

Second container 14 is shaped and sized to couple or nest with recesses 16. In the illustrated embodiment, recesses 16 extend sufficiently far into the outer surface of first container 12 to allow second containers 14 to complete a substantially cubic outer profile of the container assembly when coupled with first container 12. Such a profile corresponds with a substantially cubic inner cavity of a cage 18 for a secure fit, as discussed in detail below. However, it will be apparent to one of ordinary skill in the art that other shapes and profiles of the recesses in the first container may be employed without departing from the spirit and scope of the present invention. For example, the recess may be configured to prevent lateral movement of the second container even when the first container is not in the cage, such as by forming the recess as a cavity in the top portion of the container or by forming a retaining wall around the perimeter of the recess to form a cavity, with the second container being lowered in to the cavity to couple with the first container.

Second container 14 has a closed body shape forming a cavity therein. The second container wall has generally vertical parallel wall portions with a generally horizontal bottom portion corresponding with horizontal platform 16 a of first container 12 (discussed above). The top portion of the second container 14 has sloping sides and a handle portion 14 b integrally formed as part of the container. Adjacent the handle at the top portion is a cap 15 adapted to attach to the container and substantially seal any contents inside the container. In the illustrated embodiment, second container 14 has a generally rectangular shape, though the container may take other shapes without departing from the spirit and scope of the present invention.

The first or main container includes multiple sealable apertures at its top portion 20. In the illustrated embodiment, first container 12 includes a primary or central aperture 22, with a secondary aperture 24 and a tertiary aperture 26 located at opposite ends of primary aperture 22 (see FIG. 2). Primary aperture 22 includes a threaded exterior portion 28 adapted to threadably couple with a cap 30, with a gasket 32 being optionally interposed between cap 30 and primary aperture 22 to facilitate sealing of the primary aperture. Cap 30 may include a venting device 34 attached at a central portion of cap 30 to prevent or relieve any pressure differential between the interior cavity of the first container and the atmosphere around the container.

Secondary aperture 24 is sealed with a second venting device 36, also operable to prevent or relieve pressure differentials, such as during pouring or draining of the contents of first container 12. Tertiary aperture 26 is closed or sealed by a plug 38, such as a two inch buttress plug, which may be removed for pouring the contents of first container 12 through tertiary aperture 26. For example, if the contents of first container 12 are poured through tertiary aperture 26, venting device 34 and/or second venting device 36 may be opened to allow ambient air to flow into the container. As the contents of the container are discharged through tertiary aperture 26, the air admitted by venting devices 34, 36 smoothly displaces the poured contents as they flow out of first container 12. Although the illustrated embodiment includes three aligned apertures, it will be apparent to one of ordinary skill in the art that other combinations or configurations of apertures through the container may be employed without departing from the spirit and scope of the present invention.

Bulk container 10 includes a cage 18 that provides protection for containers 12, 14 and promotes safe and efficient transport and storage of the substances contained therein. As best seen in FIG. 1, cage 18 includes a base or bottom portion 40 that supports first container 12 and provides a stable foundation for bulk container 10. A wall 46 extends upwardly from base 40 to form a cavity 48 adapted to enclose the container or containers. Ribs 50 extend downwardly from base portion 40 to form legs 42 and upwardly from base portion 40 to form an upper outer perimeter 52 of wall 46. Legs 42 are extend below the lower face of cavity 48 with channels 44 extending between legs 42 across the width of cage 18. Channels 44 may, for example, allow a lifting device such as the forks of a forklift to pass therethrough to facilitate lifting bulk container 10 from the bottom. At the base portion 40, wall 46 curves inwardly to define the lower surface of cavity 48 that supports first container 12. In the central portion of the inwardly curved surfaces, protrusions 51 extend downwardly to support, for example, forks of a forklift as discussed above. Depressions 50 a are formed between ribs 50 with radiused transitions for enhanced strength and rigidity of cage 18.

In the illustrated embodiment, cavity 48 is adapted to receive first container 12 and second containers 14 by having a substantially cubic shape corresponding with the substantially cubic shape of the container assembly (as discussed above), although the containers and cage may be formed in other shapes. Depressions 50 a gradually flare outwardly as they approach upper outer perimeter 52 (see FIG. 1) to provide an oversize opening at the top of cavity 48 to facilitate alignment of containers 12, 14 with cavity 48 as the containers are lowered in to cage 18, as discussed in detail below. As containers 12, 14 move down in to cavity 48, the inner perimeter of the central and lower portions of wall 46 contracts to hold containers 12, 14 securely with little or no clearance for lateral movement of the containers.

When the containers 12, 14 are placed in cage 18, upper outer perimeter 52 of cage 18 extends above the upper surfaces of the containers for protection and to allow stacking of multiple bulk containers (as discussed below). Upper outer perimeter 52 is substantially open to allow ingress and egress of containers 12, 14 by lifting or lowering the containers in to or out of the cage.

Optionally, cage 18 may include apertures 54 passing through wall 46 at upper outer perimeter 52 (see FIG. 1). Apertures 54 may be used to secure bulk container 10 to a lower or supporting surface, such as a pallet or truck bed. Apertures 54 may also be used to lift or support bulk container 10 from above, such as with a forklift or overhead crane. For example, forks of a forklift may be passed through apertures 54 to securely couple bulk container 10 with the forklift for safe and efficient transport of the bulk container.

At least two substances may be stored and transported using bulk container 10. The first substance is transferred to first container 12 through an aperture in upper surface 20 (discussed above), such as through primary aperture 22. Graduation markings 56 may be provided at the exterior portion of first container 12 to aid in accurately transferring a desired amount of the first substance to the first container. First container 12 is then closed and sealed using cap 30, venting devices 34, 36 and plug 38, as discussed above. A second substance is transferred to a second container 14, and second container 14 is then closed and sealed with cap 15. First container 12 is then lowered into the cavity 48 of cage 18. Once first container 12 is firmly seated in cavity 48, and in contact with the upper interior surface of lower portion 40, second container 14 is lowered into recess 16 to couple therewith, securing second container 14 between the outer surface of first container 12 and the inner surface of wall 46 and thereby forming a substantially unitary bulk container 10. Other substances or additional quantities of the second substance may be transferred to subsequent second containers 14 as necessary, and additional second containers 14 are similarly coupled with respective recesses 16.

With containers 12, 14 securely stowed in cage 18, the first and second substances contained in their respective containers can be safely stored or transported. When transporting bulk container 10, containers 12, 14 may be secured against vertical movement by placing an obstruction, such as a strap or bar, across upper outer perimeter 52 through apertures 54. Alternatively, the bottom portion of a second cage may enclose the cavity 48 when the second cage is stacked on the first cage (as discussed in detail below). Upon reaching a destination or being removed from storage, second container 14 is removed from recess 16 and the second substance contained therein is be placed in fluid communication with the first substance contained in first container 12 to form a mixture. In the illustrated embodiment, bulk container 10 includes four second containers 14, thereby providing for a mixture of up to five different substances.

Optionally, the first container may include a drain valve assembly 62 for discharging the substance contained therein. Referring now to FIG. 3, drain valve assembly 62 of the illustrated embodiment includes a split ring assembly 64, a coupler 66, and a valve 68, with O-rings 70 interposed between each. Optionally, valve assembly 62 may also include a dust cap 72. Valve assembly 62 attaches at a bottom portion of first container 12 for draining the substance or a mixture of substances contained in the first container. Valve 68 includes a lever 74 which can be rotated between a closed position and an open position, with the open position allowing a flowable substance to pass therethrough and the closed position being substantially sealed or closed to prevent such passage.

To accommodate drain valve assembly 62, first container 12 may include a recessed portion 75, such as a cup-shaped portion (see FIG. 3) in the bottom portion of the first container. The recess may be generally semi-cylindrical in shape, with the axis of the cylinder being approximately coincidental with the bottom outer surface of the first container so that the recess extends upwardly in to the body of the first container, thereby allowing drain valve assembly 62 to couple with first container 12 without increasing the footprint of the container. The terminal end of the recess is offset from the outer wall of first container 12 so that the recess extends a portion of the bottom portion, such as about halfway across. Ribs 75 a may be included at the inwardly facing surface of recess 75 to add structural support and reinforcement to the recess. A spout or protrusion 75 b extends into the recessed portion 75 and provides a port for the first container which is in fluid communication with the interior cavity of first container 12. Drain valve assembly 62 connects to spout 75 b to dispense the contents of first container 12, as discussed above.

Cage 18 may include an opening 76 at its bottom portion corresponding with the location of drain valve assembly 62 when first container 12 is located in the cage. Opening 76 eliminates the need for removal of the first container from the cage when draining the substance in first container 12 by allowing passage through drain valve assembly 62 and opening 76. Optionally, a cover or door 78 may be pivotally coupled to the cage at opening 76 to conceal and protect the drain valve assembly. A protrusion 80 adjacent one side of opening 76 provides a stop and prevents further rotation of door 78 when the door is in the closed position, while allowing free rotation of the door to the open position.

Optionally, the cage may include keys 82 at each corner of upper outer perimeter 52. Keys 82 fit into corresponding recesses 84 in the outer surface of legs 42. Thus, a cage with keys 82 provides for precise and secure stacking of multiple bulk containers 10. The keys prevent lateral shifting of an upper bulk container stacked on a lower bulk container. The upper container is also prevented from falling into the lower container (as might occur in the event of a lateral shift of the upper container), enhancing the safety and security of the substances contained therein.

Optionally, first or main container 12 includes a recessed area 86 for placement of text or symbols or warnings or the like. In addition, the upper surface 20 of first container 12 may include a label 88 (see FIG. 2) affixed thereto for information, warnings, port specifications related to the destination of the bulk container, or the like.

Changes and modifications to the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents. 

1. A bulk container for storage of at least two substances comprising: a first container adapted to contain a first substance, wherein an outer surface of said first container includes a recess; a second container adapted to contain a second substance, said second container having a shape corresponding with said recess; wherein said second container couples with said recess to form a container assembly; and wherein said first substance and said second substance are kept separate when in said first container and said second container respectively.
 2. The bulk container as claimed in claim 1, further comprising a cage for said first and second containers, said cage comprising: a base portion supporting a bottom portion of said first container; a wall substantially surrounding said first container; and an upper outer perimeter extending above said first container when said first container is in said cage.
 3. The bulk container as claimed in claim 2 wherein said upper outer perimeter of said cage is substantially open, wherein said first container is lowerable in to said cage through said opening.
 4. The bulk container as claimed in claim 3 wherein said recess is at a top portion of said first container, wherein said second container is removable through said opening at said upper outer perimeter of said cage.
 5. The bulk container as claimed in claim 2 wherein said cage comprises a plurality of apertures passing through said wall at said upper outer perimeter.
 6. The bulk container as claimed in claim 2 wherein said recess of said first container is located adjacent said wall of said cage when said first container is in said cage, wherein said second container is between said outer surface of said first container and an inner surface of said wall when said second container is coupled with said recess.
 7. The bulk container as claimed in claim 1 wherein said first container comprises a drain valve assembly at a bottom portion of said first container.
 8. The bulk container as claimed in claim 1 wherein said first container has a capacity of at least 454 liters.
 9. The bulk container as claimed in claim 8 wherein said first container has a capacity of less than 3000 liters.
 10. The bulk container as claimed in claim 1 wherein at least one of said first container and said second container is made of an elastomeric material.
 11. The bulk container as claimed in claim 10 wherein said elastomeric material comprises polyethylene.
 12. The bulk container as claimed in claim 1 wherein said first container comprises a sealable aperture at a top portion of said first container.
 13. The bulk container as claimed in claim 1 wherein an outer perimeter of said first container comprises four corner portions, and said recess comprises four recesses each located at a respective corner portion, wherein four of said second containers are located in respective recesses.
 14. A bulk container for separately storing at least two substances comprising: a first container, wherein an outer surface of said first container includes a recess; a second container, said second container having a shape corresponding to said recess; a cage having a base portion supporting said first container, a wall substantially surrounding said first container and said second container, and an upper outer perimeter extending above said first container when said first container is in said cage; and wherein said second container couples with said recess between said wall of said cage and said outer surface of said first container to form said bulk container.
 15. A method of separately storing at least two substances comprising: placing a first substance in a first container, said first container having a recess; placing a second substance in a second container, said second container being shaped to correspond with said recess; placing said second container in said recess to form a container assembly.
 16. The method as claimed in claim 15 further comprising lowering said first container in to a cage, wherein a wall of said cage substantially surrounds said first container when in said cage.
 17. The method as claimed in claim 16 further comprising lowering said second container in to said recess, wherein said recess defines a space adapted to receive said second container, said space being between an interior surface of said wall and an outer surface of said first container.
 18. The method as claimed in claim 17 further comprising: transporting said bulk container to a destination; removing said second container from said recess at said destination; and placing said second substance in fluid communication with said first substance to form a mixture of said at least two substances.
 19. The method as claimed in claim 18 further comprising draining at least a portion of said mixture from said first container through a drain valve at a bottom portion of said first container.
 20. The method as claimed in claim 15 wherein placing said first substance in said first container comprises flowing said substance through a sealable aperture in a top portion of said first container. 